CTA Report, Draft 1, ISP Review - US Chemical Safety and Hazard ...

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10. The Kentucky State Fire Marshal’s office had not inspected the facility since it was constructed in 1972. 11. Despite frequent inspections, none of CTA’s insurers identified phenolic resin dust as an explosion hazard after 1995. 16
3.0 Facility Description 3.1 CTA Acoustics Corbin Facility The 302,000-square-foot CTA facility is located just outside the Corbin city limits in Laurel County, Kentucky. The facility employed 561 full-time personnel at the time of the incident. Operations employees worked rotating 12-hour shifts, while the mechanical department and administrative support staff worked 5-day, 8-hour shifts. CTA is a privately held company, with a technical and sales office in Madison Heights, Michigan. The Corbin facility is its only manufacturing plant. At the time of the incident, CTA had annual sales of $80 to $90 million. 3.2 Surrounding Community The neighborhood surrounding the CTA facility is part of an unincorporated community consisting of houses, apartments, and trailer homes. A nursing home, medical clinic, and elementary school are located within one mile of the plant. On the day of the incident, a number of people living or working in the area were evacuated, but no injuries to the public were reported. As a precaution, officials shut down 12 miles of Interstate 75, located approximately 0.5 mile west of the facility. 3.3 History of the Plant CertainTeed Corporation—a manufacturer of insulation, roofing, siding, windows, and related products— built the Corbin plant in 1972 and operated it for 20 years. Headquartered in Valley Forge, Pennsylvania, CertainTeed employs 7,000 people at 40 manufacturing facilities throughout the United States. In 1988, CertainTeed became a wholly owned subsidiary of Saint-Gobain. Saint-Gobain employs approximately 26,000 people in North America and more than 170,000 people in 46 countries worldwide. Saint- 17
Page 1 and 2: KEY ISSUES: U.S. CHEMICAL S AFETY A
Page 3 and 4: 5.1.2 Line 405 Oven Temperature Con
Page 5 and 6: 9.1 FM Global Guidelines...........
Page 7 and 8: Figures 1 Simplified Layout of CTA
Page 9 and 10: ACC American Chemistry Council Acro
Page 11 and 12: Executive Summary A February 20, 20
Page 13 and 14: 1.0 Introduction At approximately 7
Page 15: 2.0 Key Findings 1. Combustible phe
Page 19 and 20: eams. Nonload-bearing masonry block
Page 21 and 22: Thirteen-foot-high freestanding enc
Page 23 and 24: 4.0 Process Description The product
Page 25 and 26: 4.1.2 Mat-former and Baghouse In th
Page 27 and 28: Circulating fans and dampers direct
Page 29 and 30: • Manually striking baghouse bags
Page 31 and 32: 5.0 Incident Description 5.1 Pre-In
Page 33 and 34: • The line was one week past due
Page 35 and 36: forklift with a semi-enclosed cab d
Page 37 and 38: panels and lights down inside the b
Page 39 and 40: occurred in the southeast corner of
Page 41 and 42: 5.3.3 Firefighting Activities 5.3.3
Page 43 and 44: 5.4 Incident Aftermath The CTA inci
Page 45 and 46: 6.0 Understanding Combustible Dust
Page 47 and 48: As depicted in Figure 11 (Eckhoff,
Page 49 and 50: Figure 12. Mechanism for a dust fir
Page 51 and 52: 7.0 Reconstructive Analysis To dete
Page 53 and 54: urned clean but otherwise intact an
Page 55 and 56: 7.1.2 Other Possible Initiating Eve
Page 57 and 58: Table 3 Borden Chemical Black Pheno
Page 59 and 60: 7.3 Line 405 Equipment Testing CSB
Page 61 and 62: determine if those products are haz
Page 63 and 64: that the phenolic resin could explo
Page 65 and 66: A 1998 internal Borden Chemical mem
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• Characterize new and existing p
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CTA that phenolic resins, when susp
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CTA department supervisors were res
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8.5 Work Practices 8.5.1 Production
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operating the oven with the doors o
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8.7 Incident Investigations The inc
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• Excessive accumulations of comb
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Data Sheet 6-9 also states: Clean o
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Table 5 Insurance Company Dust Issu
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standards (Appendix D). Kentucky OS
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10.2.2 Division of Building Codes E
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11.0 Combustible Dust Hazard Study
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4. The Borden Chemical product stew
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13.0 Recommendations CSB developed
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Kentucky Office of Occupational Saf
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BY THE U.S. Chemical Safety and Haz
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Lawson, Robert G., 1984. Beverly Hi
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APPENDIX A: Fire and Explosion Dama
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APPENDIX B: Laboratory Testing of P
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B.2 Minimum Explosible Concentratio
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B.4 Propagating Brush Discharge Ign
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Material Corona Charge Voltage (kV)
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APPENDIX C: Equipment Testing Line
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II controllers, only manufactured a
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Therefore, at any given time, it wa
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APPENDIX D: NFPA Guidelines In prom
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D.2 Other Pertinent NFPA Codes D.2.
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APPENDIX E: HMIS Rating System The
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APPENDIX F: Simplified Organization
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Subtree A Second dust explosion abo
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Subtree C Most CTA personnel had a
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